Welding Inspection & Metallurgy API ICP Self Study Notes

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This recommended practice provides guidance to the API authorized inspector on welding inspection as encountered with fabrication and repair of (a) refinery and (b) chemical plant equipment and piping.
Keywords: Fulfilling their role implementing API 510, API 570, API Std 653 and API RP 582.- 4 Standards!
Page 1: Welding Inspection & Metallurgy API
Page 5 and 6: API 577 - Advanced Welding Inspecti
Page 7: This recommended practice provides
Page 10 and 11: Speaker: Fion Zhang 2014/5/4
Page 12 and 13: 5 WELDING PROCESSES 5.1 General 5.2
Page 14 and 15: 9 NON-DESTRUCTIVE EXAMINATION 9.1 D
Page 16 and 17: 11 REFINERY AND PETROCHEMICAL PLANT
Page 18 and 19: Content: 1 SCOPE
Page 20 and 21: This recommended practice provides
Page 28 and 29: API 577 is to aid the inspector in
Page 30 and 31: API Std 653 Tank Inspection, Repair
Page 32 and 33: How this API Standard relates with
Page 34: Typical E&P services are vessels as
Page 49 and 50: Keywords: The level of learning and
Page 52 and 53: This recommended practice does not
Page 54 and 55: This recommended practice does not
Page 58 and 59: The importance, difficulty, and pro
Page 60: A welding engineer should be consul
Page 64 and 65: Content: 2 REFERENCES 2.1 Codes and
Page 66 and 67: API • API 510 Pressure Vessel Ins
Page 68 and 69: AWS • A2.4 Standard Symbols for W
Page 70 and 71: API • RP 572 Inspection of Pressu
Page 72 and 73: 3 Definitions
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The following definitions apply for
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3.2 air carbon arc cutting (CAC-A):
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Arc blow
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3.6 arc welding (AW): A group of we
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Crack
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3.20 distortion: The change in shap
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HAZ
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HAZ
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HAZ http://www.twi-global.com/techn
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Hot Cracking
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Hot cracking These cracks are known
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Both solidification cracking and ho
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Inspector: An individual who is qua
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Qualified & Certified Inspectors
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Qualified & Certified Inspectors
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Figure A-1—Joint Types and Applic
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3.36 lack of fusion (LOF): A non-st
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Lamellar tear
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3.41 nondestructive examination (ND
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PMI
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PMI
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PMI
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This is API 577 special way of defi
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3.51 root face: The portion of the
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Slag Inclusion
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Slag Inclusions
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3.58 throat theoretical: The distan
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3.22 fillet weld size: For equal le
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Transverse Cracks
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Tungsten Inclusions - TIG Welding
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TIG Welding - Tungsten Inclusions
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3.64 welder certification: Written
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3.69 weld reinforcement: Weld metal
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weld toe weld reinforcement
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weld toe weld reinforcement
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Content: 4 WELDING INSPECTION 4.1 G
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4.2 TASKS PRIOR TO WELDING The impo
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4.2.1 Drawings, Codes, and Standard
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i. Preheat requirements and accepta
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Review requirements for the weldmen
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4.2.2.1 Quality control items to as
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4.2.4 NDE Information Confirm the N
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Welding Equipment and Instruments
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4.2.6 Heat Treatment and Pressure T
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4.2.7 Materials Ensure all filler m
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Materials
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Weld Preparation- Fit-up & Dimensio
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4.2.10 Welding Consumables Confirm
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4.3.1 Quality Assurance Establish a
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. Mock-up weldment, if required, me
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In-process ferrite measurement
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In-process ferrite measurement Why
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Schaeffer diagram
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4.4.1 Appearance and Finish Verify
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Field hardness check
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4.4.2 NDE Review Verify NDE is perf
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4.4.3 Post-weld Heat Treatment Veri
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PWHT Procedure
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Metal temperature of component meet
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4.5 NON-CONFORMANCES AND DEFECTS At
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4.7 SAFETY PRECAUTIONS Inspectors s
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Sevan Driller I
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5 Welding Processes
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Equipments & Piping
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Equipments & Piping
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Equipments & Piping
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Equipments & Piping
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5.2 SHIELDED METAL ARC WELDING (SMA
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5.2.2 Advantages of SMAW Some commo
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Shielded metal arc welding
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SMAW
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SMAW- Underwater Welding
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SMAW- Qualification of Underwater W
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SMAW- Structural Welding
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SMAW- Transmission Pipeline Welding
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SMAW- Weld Profile
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SMAW- Weld Profile
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SMAW- Weld Profile
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SMAW- Weld Profile
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SMAW- Grinding at Start-Stop
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SMAW- Root Pass + Hot Pass
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SMAW- Pipeline Tie-in Joint
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SMAW- WPQ Test Coupon
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SMAW- WPQ Test Coupon
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SMAW- Smiling Experts at Work
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Gas tungsten arc welding
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Gas tungsten arc welding
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GTAW
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5.3.1 Advantages of GTAW Some commo
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GTAW / TIG Weld a. Produces high pu
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GTAW / TIG Weld
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Tungsten Electrodes
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Tungsten Electrodes
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Tungsten- Automation
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Gas metal arc welding GMAW / MIG (m
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GMAW http://www.docslide.com/gmaw-f
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GMAW CV
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5.4.1 Short Circuiting Transfer (GM
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Short Circuit mode http://www.ualbe
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5.4.2 Globular Transfer This proces
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Globular transfer mode http://www.u
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Globular transfer mode http://www.w
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5.4.3 Spray Transfer The spray tran
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5.4.4 Advantages of GMAW Some commo
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Pulsed GMAW - Modified Spray Mode h
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GMAW-MIG CV
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GMAW-MIG CV
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GMAW-MIG CV
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GMAW- Automation
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GMAW- Automation
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GMAW- Stainless Steel Piping
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5.5 FLUX CORED ARC WELDING (FCAW) F
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FCAW CV
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FCAW-Self shield CV
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FCAW
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FCAW
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3G FCAW WPQT
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FCAW http://www.brewerweldingandfab
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5.6 SUBMERGED ARC WELDING (SAW) Sub
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SAW CV
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Submerged arc welding (SAW)
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SAW- Triple Electrodes Set-up (tilt
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SAW - Experts at Work
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Spiral Welded SAW Pipes
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SAW- Vessel Internal Welding
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SAW- Spiral Welded Pipes
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SAW- Serious Experts at Work
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SAW- Vessel Ellipsoidal Disk Head
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SAW- Pipe Can Welding
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SAW- Structural Welding
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5.7.1 Advantages of SW Some commonl
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Stud arc welding (SW)
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Stud arc welding (SW)
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Welding Transfer Modes: SMAW - CC T
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1.0 Considering the benefits of pul
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1.3 The short-circuit process In th
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The short-circuit process is not a
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By using 0.035- and 0.045-in.-dia.
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1.6 Summary Equipment for short-cir
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2.0 Understanding transfer modes fo
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2.1 Short-circuit Transfer In short
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Maintaining a constant contact tip-
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Stainless steel GMAW electrodes nor
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Spray Transfer Mode Shield Gas & Tr
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This transfer mode is used mostly i
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2.4 Pulse-Spray Transfer Mode In th
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3.0 Pulsed GMAW Pulsed GMAW is tech
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CV/CC Current Transfer Modes: Volta
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5. Other Interesting Reading: 5.1 C
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6: Welding Procedure
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WPS/PQR
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6.1 GENERAL Qualified welding proce
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construction codes and proprietary
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WPS 6.2 WELDING PROCEDURE SPECIFICA
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ASME B31.3, Chapter V Fabrication,
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6.2.1 Types of Essential Variables
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These requirements should be reflec
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Section IX requires that the manufa
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Mechanical Testing
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Mechanical testing- Tensile Testing
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Tensile testing: Stress Strain Diag
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Calculation of Tensile Properties o
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Weld Hardness Test
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Charpy Impact Testing
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Guided Bend Test
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Guided Bend Test
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6.4 REVIEWING A WPS AND PQR Inspect
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For simplicity purposes, the follow
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6.4.1 Items to be Included in the W
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y. Tungsten electrode size and type
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q. Electrical Characteristics. r. T
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WPS for Offshore Spar
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WPS for Offshore Spar
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WPS for Process Piping
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7: Welding Materials
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SAW
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7.2 P-NUMBER ASSIGNMENT TO BASE MET
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7.3 F-NUMBER ASSIGNMENT TO FILLER M
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Keywords: 1. Consideration should b
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F-Numbers
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7.5 A-NUMBER (filler metal) To mini
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7.6 FILLER METAL SELECTION Inspecto
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To reduce exposure to moisture, wel
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Content: 8 WELDER QUALIFICATION 8.1
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8.2 WELDER PERFORMANCE QUALIFICATIO
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Welder performance qualification ex
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j. Backing gas used. k. Metal trans
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9: Non-destructive Examination
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ASME V Article Numbers: Gen Article
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Discontinuities
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NDT Capability: Table 4
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NDT Capability: Table 5
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Table 6- Discontinuities Commonly E
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9.2 MATERIALS IDENTIFICATION During
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PMI
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9.3 VISUAL EXAMINATION (VT) 9.3.1 G
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ASME Section V, Article 9, (Paragra
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Vision Test
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Robotic Visual Inspection Crawler
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Remote Control Visual Inspection Cr
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3. Magnifiers- helpful in bringing
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Mirrors
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9.3.2.2 Mechanical Aids a. Steel ru
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Angle Ruler
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Feeler Gauge
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Vernier scale- a precision instrume
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Gap Gauge and Thickness Gauge
Page 519 and 520:
Depth Gauge
Page 521 and 522:
Bridge Cam Gage
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Adjustable fillet weld gauge
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Measures the angle of the vertical
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Weld fillet gauge being used to det
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d. Weld size gauge (see Figure 19)
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Hi-lo welding gauge
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Digital pyrometer
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What The Expert Say: http://youtu.b
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MPI
Page 539 and 540:
The pattern formed by the particles
Page 541 and 542:
MPI
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MPI
Page 546 and 547:
Some of the requirements listed in
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Pie gauge
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Pie Gauge
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MT Calibration Shims
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MT-Calibration Shims
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MT- Wet fluorescent magnetic partic
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MT Magnetic Particle Testing
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Jack-up drilling rig
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Drilling Rig in Operations
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MT-Underwater
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Magnetic Particle Testing
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9.4.3 Demagnetization When the resi
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Demagnetization
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Gauss Meter
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9.5 ALTERNATING CURRENT FIELD MEASU
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ACFM uses a probe similar to an edd
Page 588 and 589:
Two components of the magnetic fiel
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ACFM- Paint Removal is Not Necessar
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Further Reading on ACFM
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The ACFM Technique The ACFM method
Page 597 and 598:
Figure 1 B z B Z
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Specialist Windows software is used
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Once a defect is identified the dep
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ACFM: This benefit is used to good
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ACFM http://www.tscinspectionsyste
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http://www.ndt.net/article/v08n09/w
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9.6 LIQUID PENETRANT EXAMINATION (P
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A limitation of PT is that standard
Page 613 and 614:
Figure 28—Florescent Penetrant Te
Page 615 and 616:
Some requirements listed in this ar
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PT- Color Contrast Method
Page 619 and 620:
Page 621 and 622:
Page 623 and 624:
Page 625 and 626:
PT- Fluorescent Method
Page 627:
Eddy current uses a magnetic field
Page 639 and 640:
RT principles
Page 641 and 642:
RT profile radiography
Page 643 and 644:
RT- X Ray
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RT-Source http://tv.sohu.com/upload
Page 647 and 648:
RT- Gamma Ray
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RT- Gamma Ray
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X-Ray Machine
Page 653 and 654:
RT- Gamma Ray
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X-Ray Crawler
Page 657 and 658:
Golden Joint
Page 659 and 660:
RT- Techniques
Page 661:
RT- Techniques
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RT- Interpretations
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Digital RT
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An NDT examiner interprets and eval
Page 671 and 672:
Break Time mms://a588.l3944020587.c
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IQI- Image Quality Indicators
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IQI- Image Quality Indicators ASTM
Page 678 and 679:
Page 680:
IQI Placement
Page 684 and 685:
IQIs (penetrameters) are tools used
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Hole type IQI
Page 688:
Page 691 and 692:
Hole type IQI
Page 693 and 694:
RT Film coverage & overlaps Locatio
Page 695 and 696:
Keywords: (exam questions) Ir 192 C
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Gamma Ray Radiography: Source
Page 699 and 700:
Gamma Ray Radiography: Source
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Ir191- Ir 192 is typically supplied
Page 703 and 704:
Ir192
Page 705 and 706:
The gamma spectrum is shown in Fig.
Page 707 and 708:
Co 60
Page 709 and 710:
Search dosimeter-radiometer MKS-11
Page 711 and 712:
Film processing
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9.8.6 Surface Preparation Where a s
Page 715:
RT Films
Page 718 and 719:
9.8.8 Radiographic Techniques The m
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Planar defects
Page 722 and 723:
Planar & Volumetric defects
Page 724 and 725:
9.8.8.1 Single-wall Technique A sin
Page 726:
9.8.8.3 Double-wall Technique When
Page 729 and 730:
For double-wall viewing of welds, t
Page 731 and 732:
DWDI-DWV Double wall, double images
Page 733 and 734:
DWDI- Superimposed
Page 735 and 736:
9.8.9.1 Facilities for Viewing Radi
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9.8.9.2 Quality of Radiographs Radi
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Radiographic Density Radiographic d
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Radiographic Density I o I t https:
Page 744 and 745:
Densitometer
Page 746 and 747:
9.8.9.4 Excessive Backscatter A lea
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Because radiographic interpreters h
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i. Film manufacturer and type/desig
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X-Ray
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X-ray
Page 756 and 757:
Figure 34—Interpass Slag Inclusio
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Figure 36—Lack of Side Wall Fusio
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LOF- Lack of Side wall Fusion
Page 762 and 763:
Wagon Track
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Figure 38—Burn-through 1. A sever
Page 766 and 767:
Burn Through
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Burn Through
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Figure 40—Excessive Penetration (
Page 772 and 773:
Weld Joint
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Figure 42—Transverse Crack 1. A f
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Figure 44—Root Pass Aligned Poros
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Gen Article 1 RT Article 2 Nil Arti
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9.9 ULTRASONIC INSPECTION (UT) UT i
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Straight beam techniques are used f
Page 785:
Straight beam UT
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B-Scan
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Figure 47—C-scan
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The A-scan, as shown in Figure 45,
Page 794 and 795:
UT Testing- A-Scan
Page 796 and 797:
Article 4 requires a written proced
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The reference standard (calibration
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Calibration Blocks
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Calibration Blocks
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Calibration Blocks
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Calibration Blocks
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Calibration Blocks
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Calibration Blocks
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Calibration Blocks
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Calibration Blocks
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Calibration system checks should be
Page 818 and 819:
System checks are typically perform
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9.9.1.1 Echo Evaluation with DAC Th
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Figure 48—DAC Curve for a Specifi
Page 824:
DAC Plots
Page 827 and 828:
DAC / TCG
Page 831:
DAC Curve with a specific reflector
Page 834 and 835:
Unknown reflectors (flaws) are eval
Page 836 and 837:
UT testing
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Reading Ultrasonic testing and imag
Page 840:
Numbers to remember • Each pass o
Page 843 and 844:
UT Transducers
Page 845 and 846:
UT Transducers
Page 847 and 848:
• 10% scanning overlapped Min of
Page 849:
9.9.4 Straight Beam Examination A s
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Plate lamination checks
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Lamination Checks
Page 856 and 857:
Lamination Checks
Page 858 and 859:
Lamination Checks
Page 860 and 861:
Lamination Checks
Page 862 and 863:
Angle Beam UT http://www.ndt-ed.org
Page 864 and 865:
9.9.5 Angle Beam Examination Typica
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UT Scanning Patterns
Page 868 and 869:
Fillet weld defects
Page 870 and 871:
9.9.7 Discontinuity Evaluation and
Page 872 and 873:
The 6 dB drop technique is commonly
Page 874 and 875:
Other through-thickness sizing tech
Page 876 and 877:
The 6 dB drop technique Material Pr
Page 878 and 879:
Other through-thickness sizing tech
Page 880 and 881:
The ID Creeping wave method
Page 882 and 883:
9.9.7.3 The High Angle Longitudinal
Page 884 and 885:
AUT Vs RT http://www.olympus-ims.co
Page 886 and 887:
AUT Vs RT
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TOFD
Page 890 and 891:
The Tip Diffraction Method http://w
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Angle Beam Transducer http://www.ol
Page 894 and 895:
9.10 HARDNESS TESTING Hardness test
Page 896 and 897:
API 582- Vickers Hardness Test Prof
Page 898 and 899:
Hardness Testing
Page 900 and 901:
Hardness Testing
Page 902 and 903:
Hardness Testing
Page 904 and 905:
Weld Macro
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Hardness Testing
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Hardness Testing
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Portable Hardness Testing
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Page 915 and 916:
Page 917 and 918:
Page 919 and 920:
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Page 923 and 924:
Page 925 and 926:
9.11 PRESSURE AND LEAK TESTING (LT)
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Pressure Testing
Page 929 and 930:
Pressure Testing
Page 931 and 932:
Pressure Testing
Page 933 and 934:
Pressure Testing
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Pressure Testing
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Pressure Testing
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Pressure Testing
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Pressure Testing
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Pressure Testing- Incidence
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Pressure Testing- Risk
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Leak testing Leak testing may be re
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A wide variety of fluids and method
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Bubble Leak Test- Vacuum Box
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Leak Testing- Sensitive Leak Test
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9.12.1.2 Inspection Information a.
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10 Metallurgy
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10 Metallurgy 10.1 GENERAL Metallur
Page 981:
Knowledge of cast structures is imp
Page 984 and 985:
Fe-4Mo Phase Diagram
Page 986 and 987:
Phase Diagram http://www.slideshare
Page 988 and 989:
Weld Grains
Page 990 and 991:
HAZ Weld region Fusion Boundary Coa
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http://encyclopedia2.thefreediction
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The properties of the cast structur
Page 996 and 997:
Steel & Alloy- Grains
Page 998 and 999:
http://www.power-eng.com/articles/p
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Gases, such as hydrogen, which beco
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10.2.2 The Structure of Wrought Mat
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Cast VS. Wrought 1. Cast ingot has
Page 1006 and 1007:
Alloys may also consist of more tha
Page 1010 and 1011:
Steel & Alloy- Annealed Pearlite
Page 1012 and 1013:
Hypoeutectic Steel
Page 1014 and 1015:
1055 Steel Q&T 1055, used in swords
Page 1016 and 1017:
4140 Steel Annealed Ferrite Pearlit
Page 1018 and 1019:
10.2.3 Welding Metallurgy Welding m
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SAW Welding
Page 1022 and 1023:
Dendritic- usually solidify in the
Page 1024 and 1025:
INCONEL alloy 690 is a high-chromiu
Page 1026 and 1027:
Overlay Welding
Page 1028 and 1029:
Each weld pass applied will have it
Page 1030 and 1031:
Overlay Welding
Page 1032 and 1033:
Weld Macro- Fillet Welds
Page 1034 and 1035:
An important aspect of welding meta
Page 1036 and 1037:
10.3 PHYSICAL PROPERTIES The physic
Page 1038 and 1039:
Alloyed metals start to melt at a t
Page 1040 and 1041:
Solidus/Liquidus
Page 1042:
10.3.2 Thermal Conductivity The the
Page 1045 and 1046:
The thermal conductivity of a mater
Page 1047 and 1048:
10.3.4 Coefficient of Thermal Expan
Page 1050 and 1051:
10.3.5 Density The density of a mat
Page 1052 and 1053:
Casting Defects
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10.4 MECHANICAL PROPERTIES The mech
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Tensile testing - Tensile /Yield St
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Tensile testing - Tensile /Yield St
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Charpy impact testing
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Hardness testing- Sample polishing
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Hardness testing
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Hardness testing
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Ductility
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Ductility- Bend Tests
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When the specimen is subjected to s
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Tensile Testing
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Tensile Testing Yield point Sample
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http://practicalmaintenance.net/?p=
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10.4.2 Ductility In tensile testing
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The tensile specimen is punch marke
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One of the most common tests used i
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Bend Test Jig
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ASTM E290- Guided bend testing
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Bend Testing
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10.4.3 Hardness The hardness of a m
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Knoop and Vickers Hardness Tester .
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One Brinell test consists of applyi
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The Rockwell test is simple and rap
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The Vickers hardness value is prece
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10.4.4 Toughness The toughness is t
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Further Reading
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Online Metallurgy Course http://hyp
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Online Metallurgy Information http:
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Online Metallurgy Course http://fre
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Further Reading: http://practicalma
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Introduction The component elements
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Phase Diagram
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Austenite Austenite (γ), is a soli
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Shows the grain structure of an aus
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This secondary electron SEM image s
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Low carbon steel with a microstruct
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Figure 1. Part of the equilibrium d
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Martensite Martensite is commonly f
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Martensite https://www.flickr.com/s
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The strain energy involved in the m
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Figure 1. Part of the equilibrium d
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Bainite https://www.flickr.com/phot
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Proof Stress Re0.2% Since it is dif
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STEEL Steel is an alloy of iron, wi
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Aluminum Cables
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10.5 PREHEATING
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Preheating
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Preheating
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• Bring temperature up to preheat
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Preheat can be applied using severa
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The temperature of PWHT is selected
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Discussion: However there may also
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Typical PWHT Chart Insertion temper
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PWHT Chart
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PWHT
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PWHT
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PWHT
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PWHT
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PWHT
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PWHT
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PWHT- Local
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PWHT- Local
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PWHT- Local
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PWHT- Local
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PWHT- Equipments
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PWHT- Equipments
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PWHT- Equipments
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PWHT- Equipments
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Fun-Photo: Induction Bending Pipe b
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Fun-Photo: Induction Bending Pipe b
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Other factors can also affect harde
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http://www.azom.com/article.aspx?Ar
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Welding variables, such as heat inp
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Welding- Plate thickness & Weld Geo
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Weld Macro- Geometry
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The simplest means to determine har
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Jominy Bar
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Jominy Bar
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It may be important for the welding
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Typical Hardness Values Table 11—
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HIC
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HIC- Hydrogen Induced Cracking
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TTT Curve
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Martensite
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10.8 MATERIAL TEST REPORTS Material
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Billets/Ingots
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Billets/Ingots
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Billets/Ingots
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Billets/Ingots
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Billets/Ingots
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Billets/Ingots
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Product analysis- Pipe
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For the purposes of this publicatio
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Ductile to brittle transition tempe
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Fracture toughness
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Elevated mechanical property testin
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Further Reading
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Quiz 1) See the figure below for po
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c) 50% coarse pearlite + 25% bainit
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10.9 WELDABILITY OF STEELS
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Weldability is related to many fact
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The addition of carbon generally ma
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Typically, ■ ■ ■ Steels with
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The simplest weldability tests are
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Weldability Test- Cruciform testing
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Another approach to measuring susce
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10.10 WELDABILITY OF HIGH-ALLOYS Th
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Hot Shortness: • solidification c
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Ferrite Meter
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Coefficients of Linear Thermal Expa
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Sensitized Austenitic SS Common to
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Weld Decay http://www.corrosionclin
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Inert Backing Gas
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Inert Backing Gas
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Inert Backing Gas
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Inert Backing Gas http://www.foodpr
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Inert Backing Gas
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Inert Backing Gas http://www.juncti
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Inert Backing Gas
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Inert Backing Gas
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One of the main differences between
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Sluggish tendency- LOF
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Wider Bevel Angle & Thinner Root Fa
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Nickel Welding: The faster a nickel
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Content: 11 REFINERY AND PETROCHEMI
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11.2 HOT TAPPING AND IN-SERVICE WEL
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Hot Tapping
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Hot Tapping
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Hot Tapping
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Hot Tapping
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Hot Tapping
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Burn Through
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11.2.1 Electrode Considerations Hot
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Cellulosic type electrodes (e.g., E
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If the normal flow of liquids excee
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Points to consider: Is it 36” or
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Case Study: 1. Is it 36” or great
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Case Study: Is it 36” or greater
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11.2.3 Other Considerations To avoi
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11.2.4 Inspection Inspection tasks
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GMAW-S LOF
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Due to this inherent nature of the
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The quick freeze characteristic, wh
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Hazards
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Mechanical Integrity
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Happy Inspectors
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ICP Status http://myicp.api.org/Dir
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Welding Inspection & Metallurgy API ICP Self Study Notes

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